Door, deep draw molded door facing, and methods of forming door and facing

Abstract

The present invention relates to a wood composite panel having a major planar portion, at least one panel portion, and an inwardly extending contoured portion surrounding the panel portion and interconnecting the major planar portion and the panel portion. The contoured portion defines an inter-relationship between a vector angle and a deep draw depth that achieve a satisfactory stretch factor. The present invention also relates to a door having the disclosed wood composite door facings, and methods of forming the facing and door.

We claim as follows: 
     
       1. A door, comprising:
 a peripheral frame having first and second sides; 
 first and second wood composite door facings, each of said facings having a major planar surface having an exterior surface and an interior surface secured to said first and second sides, respectively, at least one panel portion, and an inwardly extending contoured portion surrounding said panel portion and interconnecting and integral with said major planar portion and said panel portion, said contoured portion having a vector angle and a draw depth that achieve a satisfactory stretch factor as shown in  FIG. 6 . 
 
     
     
       2. The door of  claim 1 , wherein the draw depth of said contoured portion is at least about 0.5 inch with a stretch factor of less than about 45%. 
     
     
       3. The door of  claim 1 , wherein the draw depth of said contoured portion is about 0.125 inch or less and the vector angle is at least about 85° with a stretch factor of less than about 90%. 
     
     
       4. The door of  claim 1 , wherein each of said contoured portions includes a base, said base of said first facing is aligned with and abuts said base of said second facing. 
     
     
       5. The door of  claim 4 , wherein said base of said first facing is adhesively secured to said base of said second facing. 
     
     
       6. The door of  claim 1 , wherein said major planar surface and said panel portion are coplanar. 
     
     
       7. The door of  claim 1 , further comprising a corrugated paper core disposed between said first and second facings. 
     
     
       8. The door of  claim 7 , wherein said core is adhesively secured to said first and second facings. 
     
     
       9. The door of  claim 8 , wherein said core has a thickness greater than the distance between said interior surface of said panel portion of said first facing and the corresponding interior surface of said panel portion of said second facing. 
     
     
       10. A wood composite door facing, comprising:
 a major planar portion having a first surface adapted to be exteriorly disposed and a second surface adapted to be interiorly disposed; 
 at least one panel portion; and 
 an inwardly extending contoured portion surrounding said panel portion and interconnecting and integral with said major planar portion and said panel portion, said contoured portion having a vector angle and a draw depth that achieve a satisfactory stretch factor as shown in  FIG. 6 . 
 
     
     
       11. The door of  claim 10 , wherein the draw depth of said contoured portion is at least about 0.5 inch with a stretch factor of less than about 45%. 
     
     
       12. The door of  claim 10 , wherein the draw depth of said contoured portion is about 0.125 inch or less and the vector angle is at least about 85° with a stretch factor of less than about 90%. 
     
     
       13. The door of  claim 10 , wherein each of said contoured portions includes a base, said base of said first facing is aligned with and abuts said base of said second facing. 
     
     
       14. The door of  claim 13 , wherein said base of said first facing is adhesively secured to said base of said second facing. 
     
     
       15. The door of  claim 10 , wherein said major planar surface and said panel portion are coplanar. 
     
     
       16. The door of  claim 10 , further comprising a corrugated paper core disposed between said first and second facings. 
     
     
       17. The door of  claim 16 , wherein said core is adhesively secured to said first and second facings. 
     
     
       18. The door of  claim 17 , wherein said core has a thickness greater than the distance between said interior surface of said panel portion of said first facing and the corresponding interior surface of said panel portion of said second facing.